Halsey Ostergaard

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Abstract Additive manufacturing has revolutionised the production of functional components and assemblies, offering a high degree of manufacturing flexibility. This review explores the latest advancements in additive manufacturing, focusing on its fusion-based and solid-state based technologies, and highlights the use of recycled aluminium as feedstock in these processes.

Additive friction stir deposition (AFSD) is an emerging solid-state additive manufacturing technique where material is deposited layer-by-layer. Unlike fusion-based additive manufacturing processes, AFSD relies on a rotating tool to extrude and bond feedstock material through frictional heat and pressure, keeping the material below its melting point to eliminate fusion-related defects. It is suitable for large structure fabrication due to its high deposition rate.